Stacked battery

ABSTRACT

A main object of the present disclosure is to provide a stacked battery in which an unevenness of short circuit resistance among a plurality of cells is suppressed. The present disclosure achieves the object by providing a stacked battery comprising: a plurality of cells in a thickness direction, wherein the plurality of cells are electrically connected in parallel; each of the plurality of cells includes a cathode current collector, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector, in this order; the stacked battery includes a surface-side cell that is located on a surface side of the stacked battery, and a center-side cell that is located on a center side rather than the surface-side cell; and a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell.

TECHNICAL FIELD

The present disclosure relates to a stacked battery.

BACKGROUND ART

Stacked batteries comprising a plurality of cells in a thickness direction are known; wherein each of the plurality of cells includes a cathode current collector, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector, in this order. For example, Patent Literature 1 discloses a lithium ion secondary battery comprising a plurality of unit cells, wherein each of the plurality of unit cells includes: a cathode layer provided with a cathode current collector and a cathode mixture layer; a solid electrolyte layer; and an anode layer provided with an anode current collector and an anode mixture layer. Further, Patent Literature 1 discloses a nail penetration test as a method for evaluating the safety of all solid batteries.

Also, for example, Patent Literature 2 discloses a method for producing a stacked type all solid battery wherein: the stacked type all solid battery comprises a plurality of all solid battery cells connected in a bipolar form or in a monopolar form; and each of the plurality of all solid battery cells includes a cathode current collector layer, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector layer.

CITATION LIST Patent Literatures

Patent Literature 1: Japanese Patent Application Laid-Open (JP-A) No. 2016-207614

Patent Literature 2: JP-A No. 2016-136490

SUMMARY OF DISCLOSURE Technical Problem

As described above, the nail penetration test is known as a method for evaluating the safety of all solid batteries. The nail penetration test is a test of penetrating a conductive nail through an all solid battery, and observing changes (such as a temperature change) when an internal short circuit within the battery occurs.

From detailed studies of the nail penetration test of stacked batteries comprising a plurality of all solid battery cells electrically connected in parallel, the present inventors have acquired new knowledge that the resistance of a short circuit part (short circuit resistance) in each cell varies greatly with the cell location. When a cell with low short circuit resistance and a cell with high short circuit resistance are mixed, a current flows from the cell with high short circuit resistance into the cell with low short circuit resistance. Hereinafter, this may be referred to as a “sneak current”. When the sneak current occurs, the temperature of the cell with low short circuit resistance (the cell to which the current flowed into) increases, and as the result, the battery materials are easily deteriorated.

The present disclosure has been made in view of the above circumstances, and a main object thereof is to provide a stacked battery in which the unevenness of short circuit resistance among a plurality of cells is suppressed.

Solution to Problem

In order to achieve the object, the present disclosure provides a stacked battery comprising: a plurality of cells in a thickness direction, wherein the plurality of cells are electrically connected in parallel; each of the plurality of cells includes a cathode current collector, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector, in this order; the stacked battery includes a surface-side cell that is located on a surface side of the stacked battery, and a center-side cell that is located on a center side rather than the surface-side cell; and a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell.

In the disclosure, at least one of the cathode current collector and the anode current collector in the surface-side cell may include, on a surface thereof, an oxide layer.

In the disclosure, the cathode current collector in the surface-side cell may include, on a surface thereof, a first coating layer containing a carbon material, and the cathode current collector in the center-side cell may include, on a surface thereof, a second coating layer containing a carbon material.

In the disclosure, a content of the carbon material in the first coating layer may be less than a content of the carbon material in the second coating layer.

In the disclosure, a thickness of the first coating layer may be more than a thickness of the second coating layer.

In the disclosure, when a proportion of a resistance R₂₀₀ at 200° C. with respect to a resistance R₂₅ at 25° C. is R₂₀₀/R₂₅, the R₂₀₀/R₂₅ value of the first coating layer may be more than the R₂₀₀/R₂₅ value of the second coating layer.

In the disclosure, the anode current collector in the surface-side cell may include, on a surface thereof, a third coating layer containing a carbon material, and the anode current collector in the center-side cell may include, on a surface thereof, a fourth coating layer containing a carbon material.

In the disclosure, a content of the carbon material in the third coating layer may be less than a content of the carbon material in the fourth coating layer.

In the disclosure, a thickness of the third coating layer may be more than a thickness of the fourth coating layer.

In the disclosure, when a proportion of a resistance R₂₀₀ at 200° C. with respect to a resistance R₂₅ at 25° C. is R₂₀₀/R₂₅, the R₂₀₀/R₂₅ value of the third coating layer may be more than the R₂₀₀/R₂₅ value of the fourth coating layer.

In the disclosure, one of the cathode current collector and the anode current collector in the surface-side cell may include, on a surface thereof, a coating layer containing a carbon material, and another may not include, on a surface thereof, a coating layer containing a carbon material; and one of the cathode current collector and the anode current collector in the center-side cell may include, on a surface thereof, a coating layer containing a carbon material, and another may not include, on a surface thereof, a coating layer containing a carbon material in reverse to the surface-side cell.

According to the present disclosure, since a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell, the unevenness of short circuit resistance among the plurality of cells may be suppressed in the stacked battery.

In the disclosure, when each of the plurality of cells is numbered as 1^(st) cell to N^(th) cell, in which N≥3, in order along the thickness direction of the stacked battery, the surface-side cell may be a cell that belongs to a cell region A including 1^(st) cell to (N/3)^(th) cell.

In the disclosure, the center-side cell may be a cell that belongs to a cell region B including ((N/3)+1)^(th) cell to (2N/3)^(th) cell.

In the disclosure, an average value of the contact resistance in the cell region A may be more than an average value of the contact resistance in the cell region B.

In the disclosure, when each of the plurality of cells is numbered as 1^(st) cell to N^(th) cell, in which N≥60, in order along the thickness direction of the stacked battery, the surface-side cell may be a cell that belongs to a cell region C including 1^(st) cell to 20^(th) cell.

In the disclosure, the center-side cell may be a cell that belongs to a cell region D including 21^(st) cell to 40^(th) cell.

In the disclosure, an average value of the contact resistance in the cell region C may be more than an average value of the contact resistance in the cell region D.

In the disclosure, the anode active material layer may include Si or a Si alloy as an anode active material.

Advantageous Effects of Disclosure

The stacked battery in the present disclosure effects that an unevenness of short circuit resistance among a plurality of cells is suppressed.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic cross-sectional view showing an example of the stacked battery of the present disclosure.

FIG. 2 is a schematic cross-sectional view explaining a nail penetration test.

FIG. 3 is a graph showing the relationship between the cell location and the short circuit resistance.

FIG. 4 is an equivalent circuit explaining a sneak current.

FIG. 5 is a schematic cross-sectional view explaining a nail penetration test.

FIGS. 6A to 6E are schematic cross-sectional views exemplifying a method for producing a two-stacked cell.

FIG. 7 is a graph exemplifying a voltage profile in a nail penetration test.

FIG. 8 is a schematic cross-sectional view explaining a testing method of a contact resistance test.

FIG. 9 is a schematic cross-sectional view explaining a testing method of a current breaking performance test.

DESCRIPTION OF EMBODIMENTS

The stacked battery of the present disclosure will be hereinafter described in detail. FIG. 1 is a schematic cross-sectional view showing an example of the stacked battery of the present disclosure. Stacked battery 100 shown in FIG. 1 comprises plurality of cells 10 (10A, 10B to 10H to 10N) in a thickness direction; and each of plurality of cells 10 includes cathode current collector 4, cathode active material layer 1, solid electrolyte layer 3, anode active material layer 2, and anode current collector 5, in this order. Further, plurality of cells 10 are electrically connected in parallel. A method for connecting the cells in parallel is not particularly limited, and for example, cell 10A and cell 10B shown in FIG. 1 are connected in parallel in a manner that the cells share anode current collector 5. Incidentally, two cells next to each other may or may not share cathode current collector 4 or anode current collector 5. In the latter case, for example, by providing two-layered cathode current collector 4 or two-layered anode current collector 5, the two cells next to each other have cathode current collector 4 or anode current collector 5 individually between the cells.

Also, stacked battery 100 includes surface-side cell 10X that is located on a surface side of stacked battery 100, and center-side cell 10Y that is located on a center side rather than surface-side cell 10X. Further, stacked battery 100 features a configuration that a contact resistance between cathode current collector 4 and anode current collector 5 in surface-side cell 10X is more than a contact resistance between cathode current collector 4 and anode current collector 5 in center-side cell 10Y.

According to the present disclosure, since a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell, the unevenness of short circuit resistance among the plurality of cells may be suppressed in the stacked battery. As described above, from detailed studies of the nail penetration test of stacked batteries comprising a plurality of cells electrically connected in parallel, the present inventors have acquired new knowledge that the resistance of a short circuit part (short circuit resistance) in each cell varies greatly with the cell location.

This new knowledge will be explained referring to FIG. 2. As shown in FIG. 2, nail 110 is penetrated into stacked battery 100 comprising plurality of cells 10 (10A, 10B to 10H to 10N) electrically connected in parallel. On this occasion, short circuit resistance R (R_(A), R_(B) to R_(H) to R_(N)) is determined with respect to each cell 10. As the result of such detailed studies, as shown in FIG. 3 for example, it was found out that cell 10A located on the surface side has lower short circuit resistance compared to cell 10H located on the center side. In other words, it was found out that there was the unevenness of short circuit resistance among the plurality of cells.

When a cell with low short circuit resistance and a cell with high short circuit resistance are mixed, a current flows from the cell with high short circuit resistance into the cell with low short circuit resistance. As shown in FIG. 4 for example, when a short circuit occurs within a stacked battery comprising cell 10A and cell 10H electrically connected in parallel in which short circuit resistance R_(A) of cell 10A is lower than short circuit resistance R_(H) of cell 10H, sneak current I flowing from cell 10H into cell 10A occurs in accordance with Ohm's law. When sneak current I occurs, the temperature of cell 10A rises due to Joule heating; as the result, the deterioration of the battery material easily occurs.

Although the reason why the unevenness of short circuit resistance exists among the plurality of cells is not completely clear, it is presumed as follows. As shown in FIG. 5 for example, on the surface side (such as location P₁ in FIG. 3) of the stacked battery, by penetrating nail 110 into cell 10, a state in which cathode current collector 4 and anode current collector 5 are in contact, and a state in which cathode active material layer 1 and anode current collector 5 are in contact, are presumed to occur.

Meanwhile, on the center side (such as location P₂ in FIG. 3) of the stacked battery, since the nail proceeds while dragging the fragment of each member, a state in which the cathode current collector and the anode current collector are not in contact, and a state in which the cathode active material layer and the anode current collector are not in contact, are presumed to occur. For the “state not in contact”, for example, the following states may be supposed: a state in which the fragment of the solid electrolyte layer exists between the two, and a state in which a void exists between the two. As the result, the short circuit resistance will be higher on the center side of the stacked battery.

Incidentally, the behavior of the short circuit resistance on the surface side that is opposite to the nail penetrating surface (such as location P₃ in FIG. 3) of the stacked battery may possibly vary with the constitution of the stacked battery; however, in both of the later described Reference Examples 1 and 2, the short circuit resistance was lowered. The reason therefor is presumed that, since the nail proceeds while dragging the larger amount of the fragment of each member, the cathode current collector and the anode current collector will be in a state electrically connected by the fragment with high electron conductivity.

In contrast, in the present disclosure, since a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell, the unevenness of short circuit resistance among the plurality of cells may be suppressed in the stacked battery. Specifically, by using a cell with relatively high contact resistance for the surface-side cell with low short circuit resistance, and using a cell with relatively low contact resistance for the center-side cell with high short circuit resistance, the unevenness of short circuit resistance among the plurality of cells may be suppressed. Incidentally, in the present disclosure, an inclusive term of merely “current collector” may be used for a cathode current collector and an anode current collector.

Also, the problem of suppressing the unevenness of short circuit resistance among the plurality of cells is a problem never occurs in a single cell, that is, a problem peculiar to a stacked battery. Further, in a typical all-solid-type stack battery, since all of the constituting members are solids, a pressure applied to the stacked battery during a nail penetration test will be extremely high. Since a high pressure such as 100 MPa or more at the part where the nail penetrates, and particularly, 400 MPa or more at the tip part of the nail, is applied, the management of the short circuit resistance in a high pressure condition is important. In contrast, in a liquid-based battery, since a void into where the liquid electrolyte penetrates exists in the electrode, a pressure applied to the battery during a nail penetration test will be greatly lower. That is, it is difficult to conceive of managing the short circuit resistance in a high pressure condition, based on the technique of the liquid-based battery.

1. Contact Resistance Between Cathode Current Collector and Anode Current Collector

The stacked battery of the present disclosure includes a surface-side cell that is located on a surface side of the stacked battery, and a center-side cell that is located on a center side rather than the surface-side cell. Further, a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell. Particularly, the difference of the contact resistances in a high pressure condition (such as 100 MPa) is preferably large.

The stacked battery of the present disclosure usually comprises two kinds or more of the cells with a different contact resistance between the cathode current collector and the anode current collector. Here, “surface-side cell” and “center-side cell” in the present disclosure are stipulations for specifying the cells with a different contact resistance between the cathode current collector and the anode current collector. For example, an assumed case is a stacked battery comprising two kinds of the cells (cell α and cell β) with a different contact resistance between the cathode current collector and the anode current collector. Incidentally, the contact resistances are cell α>cell β. When a plurality of cells α are stacked on the surface side of the stacked battery, any one of the plurality of cells α may be specified as the surface-side cell. Meanwhile, when a plurality of cells β are stacked on the center side of the stacked battery, any one of the plurality of cells β may be specified as the center-side cell. Also, when the stacked battery comprises three kinds or more of the cells with a different contact resistance between the cathode current collector and the anode current collector, comparing two cells with a different contact resistance among them, when the magnitude relation of the contact resistances and the locational relation of the two cells satisfy the specific conditions, one cell is specified as the surface-side cell, and the other cell is specified as the center-side cell.

The contact resistance between the cathode current collector and the anode current collector in the surface-side cell is regarded as R_(c1), and the contact resistance between the cathode current collector and the anode current collector in the center-side cell is regarded as R_(c2). The value of R_(c1)/R_(c2) under pressure of 100 MPa is, for example, 1.5 or more, and may be 10 or more. Meanwhile, the value of R_(c1)/R_(c2) under pressure of 100 MPa is, for example, 10000 or less. Also, the value of R_(c1) under pressure of 100 MPa is not particularly limited, and is, for example, 0.037 Ω·cm² or more, may be 0.047 Ω·cm² or more, and may be 0.103 Ω·cm² or more. Meanwhile, the value of R_(c1) under pressure of 100 MPa is, for example, 0.277 Ω·cm² or less. Incidentally, a method for measuring a contact resistance between the cathode current collector and the anode current collector will be explained in the later described Reference Example 1.

In the present disclosure, the contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than the contact resistance between the cathode current collector and the anode current collector in the center-side cell. The contact resistance may be adjusted, for example, by at least one of the properties of the current collector, the properties of an oxide layer formed on a surface of the current collector, and the properties of a coating layer, containing a carbon material, formed on a surface of the current collector.

(1) Property of Current Collector

The material for the cathode current collector in the surface-side cell may be different from the material for the cathode current collector in the center-side cell. Similarly, the material for the anode current collector in the surface-side cell may be different from the material for the anode current collector in the center-side cell. When materials for the current collectors are different, the contact resistance between the cathode current collector and the anode current collector will be different. “Different material” refers to a case in which at least one of the followings in relation to the current collector is different: included elements, composition, and crystal state. In the surface-side cell and the center-side cell, the cathode current collectors may contain the same material whereas the anode current collectors may contain different materials; the cathode current collectors may contain different materials whereas the anode current collectors may contain the same material; and both of the cathode current collectors and the anode current collectors may contain different materials.

(2) Property of Oxide Layer

At least one of the cathode current collector and the anode current collector in the surface-side cell may include, on a surface thereof, an oxide layer. A surface resistance increases by including the oxide layer, and the contact resistance between the cathode current collector and the anode current collector also increases. The oxide layer is preferably formed on at least the solid electrolyte layer facing side of the current collector. Also, the oxide layer is preferably, for example, an oxide layer including the same metal element as the current collector. The thickness of the oxide layer is, for example, 10 nm or more, and may be 20 nm or more. Also, the oxide layer is preferably an oxidation treated layer of the current collector. The oxidation treatment may include, for example, a heat treatment in the atmosphere. The heat treatment temperature is, for example, 150° C. or more, and may be within a range of 200° C. to 500° C.

At least one of the cathode current collector and the anode current collector in the center-side cell may include, on a surface thereof, an oxide layer. The thickness of the oxide layer in the cathode current collector of the surface-side cell is preferably lager than the thickness of the oxide layer in the cathode current collector of the center-side cell. Similarly, the thickness of the oxide layer in the anode current collector of the surface-side cell is preferably larger than the thickness of the oxide layer in the anode current collector of the center-side cell. Meanwhile, the cathode current collector and the anode current collector in the center-side cell may not include the oxide layer on a surface thereof.

(3) Property of Coating Layer Containing Carbon Material

At least one of the cathode current collector and the anode current collector in the surface-side cell may include, on a surface thereof, a coating layer containing a carbon material. Also, at least one of the cathode current collector and the anode current collector in the center-side cell may include, on a surface thereof, a coating layer containing a carbon material. Here, the coating layer of the cathode current collector of the surface-side cell may be regarded as a first coating layer, the coating layer of the cathode current collector of the center-side cell may be regarded as a second coating layer, the coating layer of the anode current collector of the surface-side cell may be regarded as a third coating layer, and the coating layer of the anode current collector of the center-side cell may be regarded as a fourth coating layer, in some cases.

The coating layer is a layer containing at least a carbon material, and may further contain a resin. Examples of the carbon material may include carbon blacks such as furnace black, acetylene black, Ketjen black, and thermal black; carbon fibers such as carbon nanotube and carbon nanofiber; activated carbon; carbon; graphite; graphene; and fullerene. Examples of the shape of the carbon material may include a granular shape.

Examples of the resin may include a thermoplastic resin. Examples of the thermoplastic resin may include polyvinylidene fluorid (PVDF), polypropylene, polyethylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene (ABS) resin, methacrylic resin, polyamide, polyester, polycarbonate, and polyacetal. The melting temperature of the resin is, for example, within a range of 80° C. to 300° C.

The thickness of the coating layer is, for example, within a range of 1 μm to 20 μm, and may be within a range of 1 μm to 10 μm.

A content of the carbon material in the first coating layer may be less than a content of the carbon material in the second coating layer. Similarly, a content of the carbon material in the third coating layer may be less than a content of the carbon material in the fourth coating layer. A surface resistance increases by decreasing the content of the carbon material in the coating layer of the surface-side cell, and the contact resistance between the cathode current collector and the anode current collector in the surface-side cell also increases. The content of the carbon material in the first coating layer or the third coating layer is, for example, 20% by volume or less, and may be 10% by volume or less. The cathode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the contents of the carbon material in the coating layers may be different. Similarly, the anode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the contents of the carbon material in the coating layers may be different.

A thickness of the first coating layer may be more than a thickness of the second coating layer. Similarly, a thickness of the third coating layer may be more than a thickness of the fourth coating layer. The contact resistance between the cathode current collector and the anode current collector in the surface-side cell increases by increasing the thickness of the coating layer of the surface-side cell. The difference of the thicknesses of the first coating layer and the second coating layer is, for example, 1 μm or more, may be 3 μm or more, and may be 6 μm or more. The difference of the thicknesses of the third coating layer and the fourth coating layer is similar to the above. The cathode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the thickness of the coating layers may be different. Similarly, the anode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the thicknesses of the coating layers may be different.

The coating layer may or may not further contain an inorganic filler. In the latter case, a coating layer with high electron conductivity may be obtained, and in the former case, a coating layer with PTC property may be obtained. PTC means Positive Temperature Coefficient, and is a property whose resistance changes with a positive coefficient according to a temperature increase. Here, the resin contained in the coating layer may possibly expand in its volume according to a temperature increase and cause a resistance increase of the coating layer. However, in stacked batteries using all solid battery cells, since a binding pressure is usually applied along the thickness direction, the resin influenced by the binding pressure deforms or flows so that sufficient PTC property cannot be exhibited in some cases. Meanwhile, by adding a hard inorganic filler to the coating layer, preferable PTC property may be exhibited even when influenced by the binding pressure. That is, the current breaking performance is high. The binding pressure is, for example, 0.1 MPa or more, may be 1 MPa or more, and may be 5 MPa or more. Meanwhile, the binding pressure is, for example, 100 MPa or less, may be 50 MPa or less, and may be 20 MPa or less.

Examples of the inorganic filler may include a metallic oxide and a metallic nitride. Examples of the metallic oxide may include alumina, zirconia, and silica, and examples of the metallic nitride may include silicon nitride. The average particle size (D₅₀) of the inorganic filler is, for example, within a range of 50 nm to 5 μm, and may be within a range of 100 nm to 2 μm. Also, the content of the inorganic filler in the coating layer is, for example, 50% by volume or more, and may be 60% by volume or more. Meanwhile, the content of the inorganic filler in the coating layer is, for example, 85% by volume or less, and may be 80% by volume or less.

The proportion of resistance R₂₀₀ of the coating layer at 200° C. with respect to resistance R₂₅ of the coating layer at 25° C. is regarded as R₂₀₀/R₂₅. The R₂₀₀/R₂₅ value of the first coating layer may be more than the R₂₀₀/R₂₅ value of the second coating layer. Similarly, the R₂₀₀/R₂₅ value of the third coating layer may be more than the R₂₀₀/R₂₅ value of the fourth coating layer. The contact resistance between the cathode current collector and the anode current collector in the surface-side cell increases when the current breaking performance of the coating layer of the surface-side cell is high. The R₂₀₀/R₂₅ value is preferably, for example, 10 or more. The cathode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the current breaking performances of the coating layers may be different. Similarly, the anode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the current breaking performances of the coating layers may be different.

Also, one of the cathode current collector and the anode current collector in the surface-side cell may include, on a surface thereof, a coating layer containing a carbon material, and another may not include, on a surface thereof, a coating layer containing a carbon material; whereas one of the cathode current collector and the anode current collector in the center-side cell may include, on a surface thereof, a coating layer containing a carbon material, and another may not include, on a surface thereof, a coating layer containing a carbon material in reverse to the surface-side cell. In this case, both of the cathode current collectors and the anode current collectors of the surface-side cell and the center-side cell may include the same material, whereas the current collectors on which the coating layers are formed may be different.

2. Constitution of Stacked Battery

Each of the plurality of cells included in the stacked battery is numbered as a 1^(st) cell to a N^(th) cell in order along the thickness direction of the stacked battery. N refers to the total cell number included in the stacked battery; for example, N is 3 or more, may be 10 or more, may be 30 or more, and may be 50 or more. Meanwhile, N is, for example, 200 or less, may be 150 or less, and may be 100 or less.

The surface-side cell is preferably a cell that belongs to a cell region including the 1^(st) cell to a (N/3)^(th) cell. Here, the (N/3)^(th) cell is a cell whose order corresponds to a value obtained by dividing the total cell number N by three. For example, when the total cell number is 60, the (N/3)^(th) cell is a 20^(th) cell. Incidentally, when the (N/3) is not an integer, the (N/3)^(th) cell is specified by rounding off to the nearest integer. Also, the surface-side cell may be, for example, a cell that belongs to a cell region including the 1^(st) cell to the 20^(th) cell, and may be a cell that belongs to a cell region including the 1^(st) cell to a 10^(th) cell.

Also, the surface-side cell may be, for example, a cell that belongs to a cell region including a 5^(th) cell to the (N/3)^(th) cell, and may be a cell that belongs to a cell region including the 10^(th) cell to the (N/3)^(th) cell. As mentioned in the later described Reference Examples 1 and 2, due to the influence of an exterior package such as a laminate film, the short circuit resistance of the 1^(st) cell during a nail penetration may be high in some cases. Therefore, the surface-side cell may be specified, excluding the 1^(st) cell and the neighborhood cells.

Meanwhile, the center-side cell is a cell that is located on the center side rather than the surface-side cell. “Center side” refers to the central side in the thickness direction of the stacked cells. The center-side cell is preferably a cell that belongs to a cell region including a ((N/3)+1)^(th) cell to a (2N/3)^(th) cell. Here, the ((N/3)+1)^(th) cell refers to a cell next to the (N/3)^(th) cell when numbered from the 1^(st) cell. Meanwhile, the (2N/3)^(th) cell is a cell whose order corresponds to a value obtained by dividing the doubled value of the total cell number N by three. For example, when the total cell number is 60, the (2N/3)^(th) cell is a 40^(th) cell. Incidentally, when the (2N/3) is not an integer, the (2N/3)^(th) cell is specified by rounding off to the nearest integer. Also, the center-side cell may be, for example, a cell that belongs to a cell region including the 21^(st) cell to the 40^(th cell.)

Also, a cell region including the 1^(st) cell to the (N/3)^(th) cell is regarded as a cell region A, and a cell region including the ((N/3)+1)^(th) cell to the (2N/3)^(th) cell is regarded as a cell region B. The average contact resistance R_(CA) in the cell region A is preferably more than the average contact resistance R_(CB) in the cell region B. The value of R_(CA)/R_(CB) under pressure of 100 MPa is, for example, 1.5 or more, and may be 10 or more. Meanwhile, the value of R_(CA)/R_(CB) under pressure of 100 MPa is, for example, 10000 or less.

Also, a cell region including the 1^(st) cell to the 20^(th) cell is regarded as a cell region C, and a cell region including the 21^(st) cell to the 40^(th) cell is regarded as a cell region D. The average contact resistance R_(CC) in the cell region C is preferably more than the average contact resistance R_(CD) in the cell region D. The value of R_(CC)/R_(CD) under pressure of 100 MPa is, for example, 1.5 or more, and may be 10 or more. Meanwhile, the value of R_(CC)/R_(CD) under pressure of 100 MPa is, for example, 10000 or less.

Also, in the present disclosure, the contact resistance between the cathode current collector and the anode current collector, under pressure of 100 MPa, in all of the plurality of cells may be 0.037 Ω·cm² or more, may be 0.047 Ω·cm² or more, and may be 0.103 Ω·cm² or more.

Also, in the stacked battery after a nail penetration test, the short circuit resistance of the cell with the lowest short circuit resistance is regarded as R_(Min), and the short circuit resistance of the cell with the highest short circuit resistance is regarded as R_(Max). For example, when a metal active material (particularly Si or an Si alloy) is used as the anode active material, the value of R_(Max)/R_(Min) is preferably 100 or less, and more preferably 5.0 or less. Incidentally, the nail penetration test is carried out under conditions mentioned in the later described Reference Examples 1 and 2.

3. Cell

The cell in the present disclosure includes a cathode current collector, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector, in this order. The cell is typically a cell utilizing Li ion conductivity (a Li ion cell). Also, the cell is preferably a cell capable of being charged and discharged (a secondary battery).

(1) Anode Active Material Layer

The anode active material layer includes at least an anode active material, and may include at least one of a solid electrolyte material, a conductive material, and a binder as required.

The anode active material is not particularly limited, and examples thereof may include a metal active material, a carbon active material, and an oxide active material. Examples of the metal active material may include a simple substance of metal and a metal alloy. Examples of the metal element included in the metal active material may include Si, Sn, In, and Al. The metal alloy is preferably an alloy including the above described metal element as the main component. Examples of the Si alloy may include a Si—Al base alloy, a Si—Sn base alloy, a Si—In base alloy, a Si—Ag base alloy, a Si—Pb base alloy, a Si—Sb base alloy, a Si—Bi base alloy, a Si—Mg base alloy, a Si—Ca base alloy, a Si—Ge base alloy, and a Si—Pb base alloy. Incidentally, the Si—Al based alloy, for example, refers to an alloy including at least Si and Al, may be an alloy including only Si and Al, and may be an alloy further including an additional metal element. It is much the same for the alloys other than the Si—Al based alloy. The metal alloy may be a two-component based alloy, and may be a multicomponent based alloy including three or more components.

Meanwhile, examples of the carbon active material may include a mesocarbon microbead (MCMB), a highly oriented pyrolytic graphite (HOPG), a hard carbon, and a soft carbon. Also, examples of the oxide active material may include a lithium titanate such as Li₄Ti₅O₁₂.

Examples of the shape of the anode active material may include a granular shape. The average particle size (D₅₀) of the anode active material is, for example, within a range of 10 nm to 50 μm, and may be within a range of 100 nm to 20 μm. The proportion of the anode active material in the anode active material layer is, for example, 50% by weight or more, and may be within a range of 60% by weight to 99% by weight.

The solid electrolyte material is not particularly limited, and examples thereof may include an inorganic solid electrolyte material such as a sulfide solid electrolyte material, and an oxide solid electrolyte material. Examples of the sulfide solid electrolyte material may include Li₂S—P₂S₅, Li₂S—P₂S₅—LiI, Li₂S—P₂S₅—LiI—LiBr, Li₂S—P₂S₅—Li₂O, Li₂S—P₂S₅—Li₂O—LiI, Li₂S—SiS₂, Li₂S—SiS₂—LiI, Li₂S—SiS₂—LiBr, Li₂S—SiS₂—LiCl, Li₂S—SiS₂—B₂S₃—LiI, Li₂S—SiS₂—P₂S₅—LiI, Li₂S—B₂S₃, Li₂S—P₂S₅-ZmSn (wherein m and n are respectively a positive number; Z is any one of Ge, Zn, and Ga.), Li₂S—GeS₂, Li₂S—SiS₂—Li₃PO₄, Li₂S—SiS₂-Li_(x)MO_(y) (wherein x and y are respectively a positive number; M is any one of P, Si, Ge, B, Al, Ga, and In.) Incidentally, the above described “Li₂S—P₂S₅” refers to a sulfide solid electrolyte material using a raw material composition including Li₂S and P₂S₅, and it is much the same for other descriptions.

In particular, the sulfide solid electrolyte material is preferably provided with an ion conductor including Li, A (A is at least one kind of P, Si, Ge, Al, and B), and S. Further, the ion conductor preferably includes an anion structure (PS₄ ³⁻ structure, SiS₄ ⁴⁻ structure, GeS₄ ⁴⁻ structure, AlS₃ ³⁻ structure, BS₃ ³⁻ structure) of an ortho-composition, as the main component of an anion. The reason therefor is to obtain a sulfide solid electrolyte material with high chemical stability. The proportion of the anion structure of the ortho-composition among the total anion structures in the ion conductor is preferably 70 mol % or more, and more preferably 90 mol % or more. The proportion of the anion structure of the ortho-composition may be determined by, for example, a Raman spectroscopy, a NMR, and an XPS.

In addition to the ion conductor, the sulfide solid electrolyte material may include a lithium halide. Examples of the lithium halide may include LiF, LiCl, LiBr, and LiI, and among them, LiCl, LiBr, and LiI are preferable. The proportion of LiX (X=I, Cl, Br) in the sulfide solid electrolyte material is, for example, within a range of 5 mol % to 30 mol %, and may be within a range of 15 mol % to 25 mol %.

The solid electrolyte material may be a crystalline material, and may be an amorphous material. Also, the solid electrolyte material may be a glass, and may be a crystallized class (a glass ceramic). Examples of the shape of the solid electrolyte material may include a granular shape.

Examples of the conductive material may include carbon materials such as acetylene black (AB), Ketjen black (KB), carbon fiber, carbon nanotube (CNT), and carbon nanofiber (CNF). Also, examples of the binder may include rubber based binders such as butylene rubber (BR), styrene-butadiene rubber (SBR); and fluoride based binders such as polyvinylidene fluoride (PVDF).

The thickness of the anode active material layer is, for example, within a range of 0.1 μm to 300 μm, and may be within a range of 0.1 μm to 100 μm.

(2) Cathode Active Material Layer

The cathode active material layer includes at least a cathode active material, and may include at least one of a solid electrolyte material, a conductive material, and a binder as required.

The cathode active material is not particularly limited, and examples thereof may include an oxide active material. Examples of the oxide active material may include a rock salt bed type active material such as LiCoO₂, LiMnO₂, LiNiO₂, LiVO₂, and LiNi_(1/3)Co_(1/3)Mn_(1/3)O₂; a spinel type active material such as LiMn₂O₄, Li₄Ti₅O₁₂, and Li(Ni_(0.5)Mn_(1.5))O₄; and an olivine type active material such as LiFePO₄, LiMnPO₄, LiNiPO₄, and LiCoPO₄. Also, as the oxide active material, for example, a LiMn spinel active material represented by Li_(1+x)Mn_(2-x-y)M_(y)O₄ (M is at least one kind of Al, Mg, Co, Fe, Ni, and Zn, and 0<x+y<2), and a lithium titanate may be used.

Also, on a surface of the cathode active material, a coating layer including a Li ion conductive oxide may be formed. The reason therefore is to suppress the reaction between the cathode active material and the solid electrolyte material. Examples of the Li ion conductive oxide may include LiNbO₃, Li₄Ti₅O₁₂, and Li₃PO₄. The thickness of the coating layer is, for example, within a range of 0.1 nm to 100 nm, and may be within a range of 1 nm to 20 nm. The coverage of the coating layer on the cathode active material surface is, for example, 50% or more, and may be 80% or more.

The solid electrolyte material, the conductive material, and the binder used for the cathode active material layer are respectively in the same contents as those described in “(1) Anode active material layer” above; thus, the descriptions herein are omitted. Also, the thickness of the cathode active material layer is, for example, within a range of 0.1 μm to 300 μm, and may be within a range of 0.1 μm to 100 μm.

(3) Solid Electrolyte Layer

The solid electrolyte layer is a layer formed between the cathode active material layer and the anode current collector. Also, the solid electrolyte layer includes at least a solid electrolyte material, and may further include a binder as required. The solid electrolyte material and the binder used for the solid electrolyte layer are respectively in the same contents as those described in “(1) Anode active material layer” above; thus, the descriptions herein are omitted.

The content of the solid electrolyte material in the solid electrolyte layer is, for example, within a range of 10% by weight to 100% by weight, and may be within a range of 50% by weight to 100% by weight. Also, the thickness of the solid electrolyte layer is, for example, within a range of 0.1 μm to 300 μm, and may be within a range of 0.1 μm to 100 μm.

(4) Cathode Current Collector and Anode Current Collector

The cathode current collector collects currents of the above described cathode active material layer, and the anode current collector collects currents of the above described anode active material layer. The metal element included in the cathode current collector is not particularly limited, and examples thereof may include Al, Fe, Ti, Ni, Zn, Cr, Au, and Pt. The cathode current collector may be a simple substance of the metal element, and may be an alloy including the metal element as the main component. Stainless steel (SUS) is an example of the Fe alloy, and SUS304 is preferable.

Examples of the shape of the cathode current collector may include a foil shape and a mesh shape. The thickness of the cathode current collector is, for example, 0.1 μm or more, and may be 1 μm or more. When the cathode current collector is too thin, the current collecting function may be degraded. Meanwhile, the thickness of the cathode current collector is, for example, 1 mm or less, and may be 100 μm or less. When the cathode current collector is too thick, the energy density of a battery may be degraded.

The metal element included in the anode current collector is not particularly limited, and examples thereof may include Cu, Fe, Ti, Ni, Zn, and Co. The anode current collector may be a simple substance of the metal element, and may be an alloy including the metal element as the main component. Stainless steel (SUS) is an example of the Fe alloy, and SUS304 is preferable.

Examples of the shape of the anode current collector may include a foil shape and a mesh shape. The thickness of the anode current collector is, for example, 0.1 μm or more, and may be 1 μm or more. When the anode current collector is too thin, the current collecting function may be degraded. Meanwhile, the thickness of the anode current collector is, for example, 1 mm or less, and may be 100 μm or less. When the anode current collector is too thick, the energy density of a battery may be degraded.

Incidentally, the present disclosure is not limited to the embodiments. The embodiments are exemplification, and any other variations are intended to be included in the technical scope of the present disclosure if they have substantially the same constitution as the technical idea described in the claim of the present disclosure and offer similar operation and effect thereto.

EXAMPLES

The present disclosure will be described in more details. First, in each of Reference Examples 1 and 2, it was confirmed that the unevenness of short circuit resistance among a plurality of cells in a conventional stacked battery was large.

Reference Example 1

Production of Cathode

Using a tumbling fluidized bed granulating-coating machine (manufactured by Powrex Corp.), the cathode active material (Li_(1.15)Ni_(1/3)Co_(1/3)Mn_(1/3)W_(0.005)O₂) was coated with LiNbO₃ in the atmospheric environment. After that, by burning thereof in the atmospheric environment, a coating layer including LiNbO₃ was formed on the surface of the cathode active material. Thereby, a cathode active material having the coating layer on the surface thereof was obtained.

Next, butyl butyrate, 5% by weight butyl butyrate solution of a PVDF based binder (manufactured by Kureha Corp.), the obtained cathode active material, a sulfide solid electrolyte material (Li₂S—P₂S₅ based glass ceramic including LiI and LiBr, average particle size D₅₀=0.8 μm), and a conductive material (a vapor-grown carbon fiber, VGCF, manufactured by Showa Denko K. K.) were added into a propylene (PP) container so as to be cathode active material:sulfide solid electrolyte material:conductive material:binder=85:13:1:1 in the weight ratio. Next, the PP container was stirred for 30 seconds by an ultrasonic dispersion apparatus (UH-50, manufactured by SMT Corp.) Next, the PP container was agitated for 3 minutes by an agitation mixer (TTM-1, manufactured by Sibata Scientific Technology LTD.), and further, was stirred for 30 seconds by the ultrasonic dispersion apparatus to obtain a coating solution.

Next, an Al foil (manufactured by Nippon Foil Mfg. Co. Ltd., a cathode current collector) was prepared. The obtained coating solution was pasted on the Al foil by a blade method using an applicator. The coated electrode was dried naturally, and then, was dried at 100° C. for 30 minutes on a hot plate to form a cathode active material layer on one surface of the cathode current collector. Next, the obtained product was cut according to the size of the battery to obtain a cathode.

Production of Anode

Butyl butyrate, 5% by weight butyl butyrate solution of a PVDF based binder (manufactured by Kureha Corp.), an anode active material (silicon, manufactured by Kojundo Chemical Lab. Co., Ltd., average particle size D₅₀=5 μm), a sulfide solid electrolyte material (Li₂S—P₂S₅ based glass ceramic including LiI and LiBr, average particle size D₅₀=0.8 μm), and a conductive material (a vapor-grown carbon fiber, VGCF, manufactured by Showa Denko K. K.) were added into a PP container so as to be anode active material:sulfide solid electrolyte material:conductive material:binder=55:42:2:1 in the weight ratio. Next, the PP container was stirred for 30 seconds by an ultrasonic dispersion apparatus (UH-50, manufactured by SMT Corp.). Next, the PP container was agitated for 30 minutes by an agitation mixer (TTM-1, manufactured by Sibata Scientific Technology LTD.), and further, was stirred for 30 seconds by the ultrasonic dispersion apparatus to obtain a coating solution.

Next, as shown in FIG. 6A, a Cu foil (anode current collector 5) was prepared. The obtained coating solution was pasted on the Cu foil by a blade method using an applicator. The coated electrode was dried naturally, and then, was dried at 100° C. for 30 minutes on a hot plate. Thereby, as shown in FIG. 6B, anode active material layer 2 was formed on one surface of the Cu foil (anode current collector 5). After that, by the similar treatment, anode active material layer 2 was formed on another surface of the Cu foil (anode current collector 5) as shown in FIG. 6C. Next, the obtained product was cut according to the size of the battery to obtain an anode.

Production of Solid Electrolyte Layer

Heptane, 5% by weight heptane solution of a butylene rubber based binder (manufactured by JSR Corp.), and a sulfide solid electrolyte material (Li₂S—P₂S₅ based glass ceramic including LiI and LiBr, average particle size D₅₀=2.5 μm) were added into a PP container. Next, the PP container was stirred for 30 seconds by an ultrasonic dispersion apparatus (UH-50, manufactured by SMT Corp.). Next, the PP container was agitated for 30 minutes by an agitation mixer (TTM-1, manufactured by Sibata Scientific Technology LTD.), and further, was stirred for 30 seconds by the ultrasonic dispersion apparatus to obtain a coating solution.

Next, an Al foil (manufactured by Nippon Foil Mfg. Co. Ltd.) was prepared. The obtained coating solution was pasted on the Al foil by a blade method using an applicator. The coated electrode was dried naturally, and then, was dried at 100° C. for 30 minutes on a hot plate. Next, the obtained product was cut according to the size of the battery to obtain a transfer member including the Al foil and the solid electrolyte layer.

Production of Evaluation Battery

Each of the two obtained transfer members was placed on the anode active material layers formed on the both sides of the anode current collector, and the product was pressed under the pressure of 4 ton/cm² by a cold isostatic pressing method (CIP method). After that, the Al foils of the transfer members were peeled off. Thereby, as shown in FIG. 6D, solid electrolyte layers 3 were formed on anode active material layers 2. Next, each of the two above obtained cathodes was placed on the solid electrolyte layers formed on the both sides of the anode current collectors, and the product was pressed under the pressure of 4 ton/cm² by the cold isostatic pressing method (CIP method). Thereby, as shown in FIG. 6E, cathode active material layers 1 and cathode current collectors 4 were formed on solid electrolyte layers 3. As described above, a two-stacked cell was obtained. Further, 30 of the obtained two-stacked cells were stacked, and the obtained product was sealed with an aluminum laminate film to obtain an evaluation battery.

Reference Example 2

Production of Anode

Butyl butyrate, 5% by weight butyl butyrate solution of a PVDF based binder (manufactured by Kureha Corp.), an anode active material (natural graphite, manufactured by Nippon Carbon Co., Ltd., average particle size D₅₀=10 μm), and a sulfide solid electrolyte material (Li₂S—P₂S₅ based glass ceramic including LiI and LiBr, average particle size D₅₀=0.8 μm) were added into a PP container so as to be anode active material:sulfide solid electrolyte material:binder=59:40:1 in the weight ratio. Next, the PP container was stirred for 30 seconds by an ultrasonic dispersion apparatus (UH-50, manufactured by SMT Corp.) Next, the PP container was agitated for 30 minutes by an agitation mixer (TTM-1, manufactured by Sibata Scientific Technology LTD.), and further, was stirred for 30 seconds by the ultrasonic dispersion apparatus to obtain a coating solution.

Production of Evaluation Battery

A two-stacked cell was obtained in the same manner as in Reference Example 1 except that the obtained coating solution was used. Further, an evaluation battery was obtained in the same manner as in Reference Example 1 except that 40 of the obtained two-stacked cells were stacked.

[Evaluation]

A nail penetration test was conducted for each evaluation battery obtained in Reference Examples 1 and 2 under the following conditions.

Charging status: uncharged

Resistance meter: RM3542 manufactured by Hioki E. E. Corp.

Nail: SK (carbon tool steel) material (ϕ): 8 mm, tip angle: 60°)

Speed of the nail: 25 mm/sec

The short circuit resistance of a cell was obtained from a voltage profile upon the nail penetration. An example of the voltage profile is shown in FIG. 7. As shown in FIG. 7, the voltage of the cell decreases by penetrating the nail. Here, the initial voltage is referred to as V₀, and the minimum voltage upon the nail penetration is referred to as V. Also, the internal resistance of the cell was measured in advance, and the internal resistance is referred to as r. Also, the short circuit resistance of the cell is referred to as R. When presuming that all of the current generated due to the voltage drop upon the nail penetration is the short circuit current, a relationship of V/R=(V₀−V)/r is established. The short circuit resistance R of the cell may be calculated from this relationship. By compiling the voltage profile of each cell, a variation of the short circuit resistance in the thickness direction was confirmed. The results thereof are shown in Table 1 and Table 2. Incidentally, the values of the short circuit resistance in Table 1 and Table 2 are relative values when the short circuit resistance of the 1^(st) cell is 1. Also, the cell close to the nail penetration surface was numbered as the 1^(st) cell.

TABLE 1 <Si> Short circuit N^(th) cell resistance  1 1 10 0.005 20 28859 30 38255 40 671141 50 18121 60 0.026

TABLE 2 <C> Short circuit N^(th) cell resistance  1 1 10 0.159 40 0.968 60 3.683 80 0.698

As shown in Table 1 and Table 2, in both Reference Examples 1 and 2, the short circuit resistance of the 1^(st) cell was more than the short circuit resistance of the 10^(th) cell. The reason therefor is presumed that upon the nail penetration, the insulating part of the laminate film was dragged in. Also, in Reference Example 1, the short circuit resistance of the 40^(th) cell was more compared to the short circuit resistance of the 1^(st) cell or the 10^(th) cell, and in Reference Example 2, the short circuit resistance of the 60^(th) cell was more compared to the short circuit resistance of the 1^(st) cell or the 10^(th) cell. As described above, the short circuit resistance was less in the surface-side cell, and was more in the center-side cell. Particularly, in Reference Example 1 in which Si was used as the anode active material, the unevenness of the short circuit resistance was extremely large compared to Reference Example 2 in which C was used as the anode active material.

Experimental Example 1

An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 2

A SUS foil (SUS304, 15 μm thickness, manufactured by Toyo Seihaku Co., Ltd.) was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 3

A Ti foil (10 μm thickness, TR207C-H manufactured by Takeuchi Kinzoku Hakufun Kogyo Co., Ltd.) was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 4

An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was prepared as a cathode current collector, and a Fe foil (10 μm thickness, manufactured by Takeuchi Kinzoku Hakufun Kogyo Co., Ltd.) was prepared as an anode current collector.

Experimental Example 5

A Fe foil (10 μm thickness, manufactured by Takeuchi Kinzoku Hakufun Kogyo Co., Ltd.) was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

[Evaluation]

The contact resistance between the cathode current collector and the anode current collector each prepared in Experimental Examples 1 to 5 was measured. Specifically, as shown in FIG. 8, anode current collector 5 was placed on bakelite plate 21, kapton film 22 having a through section was placed on anode current collector 5, and cathode current collector 4 was placed on kapton film 22. Further, SK material block 23 with ϕ11.28 mm was placed on cathode current collector 4 so as to overlap the through section of kapton film 22 in plan view. In this situation, the resistance value, when 100 MPa was applied by autograph 24, was measured by a resistance meter (RM3542, manufactured by Hioki E. E. Corp.). The results thereof are shown in Table 3.

TABLE 3 Contact resistance Cathode current Anode current [Ω · cm²] collector collector 100 MPa Experimental Al Cu 0.001 Example 1 Experimental SUS Cu 0.103 Example 2 Experimental Ti Cu 0.224 Example 3 Experimental Al Fe 0.047 Example 4 Experimental Fe Cu 0.037 Example 5

As shown in Table 3, it was confirmed that the contact resistance differs according to the material of the current collector. From these results, it was suggested that, by making the contact resistance of the surface-side cell relatively high, and by making the contact resistance of the center-side cell relatively low, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

Experimental Example 6

A heat treatment was conducted to a SUS foil (SUS304, 15 μm thickness, manufactured by Toyo Seihaku Co., Ltd.) under the condition of 200° C. for 1 hour, in the atmosphere, and an oxide layer (oxide layer of SUS) was formed on a surface thereof. The obtained SUS foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 7

A heat treatment was conducted to a SUS foil (SUS304, 15 μm thickness, manufactured by Toyo Seihaku Co., Ltd.) under the condition of 500° C. for 1 hour, in the atmosphere, and an oxide layer (oxide layer of SUS) was formed on a surface thereof. The obtained SUS foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

[Evaluation]

The contact resistance between the cathode current collector and the anode current collector each prepared in Experimental Examples 1, 2, 6 and 7 was measured. The contact resistance was measured by the method described above. Also, the resistance value when 1 MPa was applied was measured similarly. The results thereof are shown in Table 4.

TABLE 4 Cathode current Anode current Contact resistance [Ω · cm²] collector collector 1 MPa 100 MPa 1 MPa/100 MPa Experimental Al Cu 0.002 0.001 2 Example 1 Experimental SUS Cu 0.892 0.103 8.7 Example 2 Experimental SUS (200° C., 1 h) Cu 7.332 0.192 38 Example 6 Experimental SUS (500° C., 1 h) Cu 3.501 0.277 12.6 Example 7

As shown in Table 4, the contact resistance was increased by forming the oxide layer on the surface of the current collector. From these results, it was suggested that, by forming the oxide layer on the current collector of the surface-side cell, the short circuit resistance of the surface-side cell may be increased, and as the result, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

Also, as described above, in a typical all-solid-type stack battery, since all of the constituting members are solids, a pressure applied to the stacked battery during a nail penetration test will be extremely high. For example, a high pressure such as 100 MPa or more is applied to the part where the nail penetrates. Since the situations in a high pressure condition (such as 100 MPa or more) and low pressure condition (such as 1 MPa) are completely different, it is difficult to predict the short circuit resistance in a high pressure condition, based on the short circuit resistance in a low pressure condition. Actually, the rate of resistance change (1 MPa/100 MPa) in Experimental Examples 1 and 2, in which the oxide layer was not provided, was about one digit, whereas the rate of resistance change (1 MPa/100 MPa) in Experimental Examples 6 and 7, in which the oxide layer was provided, was about two digits. Accordingly, it is difficult to predict the short circuit resistance in a high pressure condition, based on the short circuit resistance in a low pressure condition.

Experimental Example 8

A paste was produced by mixing N-methylpyrrolidone (NMP) with a conductive material (furnace black, average primary particle size of 66 nm, manufactured by Tokai Carbon Co., Ltd.) and PVDF (KF polymer L #9130, manufactured by Kureha Corp.) so as to be conductive material:PVDF=20:80 in the volume ratio. An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was coated with the obtained paste so as the thickness after drying to be 10 μm, dried in a drying furnace, and a coating layer was formed. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 9

A coating layer was formed in the same manner as in Experimental Example 8 except that the volume ratio was changed to conductive material:PVDF=9:91. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 10

A coating layer was formed in the same manner as in Experimental Example 8 except that the volume ratio was changed to conductive material:PVDF=8:92. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

[Evaluation]

The contact resistance between the cathode current collector and the anode current collector each prepared in Experimental Examples 8 to 10 was measured. The contact resistance was measured by the method described above. The results thereof are shown in Table 5.

TABLE 5 Cathode current collector Anode Contact resistance C ratio current [Ω · cm2] Kind [vol. %] collector 100 MPa Experimental C coated Al 20 Cu 0.360 Example 8 Experimental C coated Al 9 Cu 2.280 Example 9 Experimental C coated Al 8 Cu 5.450 Example 10

As shown in Table 5, it was confirmed that the contact resistance differs according to the content of the carbon material in the current collector. From these results, it was suggested that, by making the content of the carbon material in the current collector of the surface-side cell relatively low, and by making the content of the carbon material in the current collector of the center-side cell relatively high, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

Experimental Example 11

A paste was produced by mixing N-methylpyrrolidone (NMP) with a conductive material (furnace black, average primary particle size of 66 nm, manufactured by Tokai Carbon Co., Ltd.) and PVDF (KF polymer L #9130, manufactured by Kureha Corp.) so as to be conductive material:PVDF=20:80 in the volume ratio. An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was coated with the obtained paste so as the thickness after drying to be 3 μm, dried in a drying furnace, and a coating layer was formed. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 12

A coating layer was formed in the same manner as in Experimental Example 11 except that the thickness of the coating layer was changed to 6 μm. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 13

A coating layer was formed in the same manner as in Experimental Example 11 except that the thickness of the coating layer was changed to 9 μm. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

Experimental Example 14

A coating layer was formed in the same manner as in Experimental Example 11 except that the thickness of the coating layer was changed to 12 μm. The obtained Al foil was prepared as a cathode current collector, and a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

[Evaluation]

The contact resistance between the cathode current collector and the anode current collector each prepared in Experimental Examples 11 to 14 was measured. The contact resistance was measured by the method described above. The results thereof are shown in Table 6.

TABLE 6 Contact Cathode current collector Anode resistance Coating thickness current [Ω · cm2] Kind [μm] collector 15 MPa Experimental C coated Al 3 Cu 0.4 Example 11 Experimental C coated Al 6 Cu 0.6 Example 12 Experimental C coated Al 9 Cu 1.2 Example 13 Experimental C coated Al 12 Cu 1.4 Example 14

As shown in Table 6, it was confirmed that the contact resistance differs according to the thickness of the coating layer. From these results, it was suggested that, by making the thickness of the coating layer in the current collector of the surface-side cell relatively high, and by making the thickness of the coating layer in the current collector of the center-side cell relatively low, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

Experimental Example 15

A paste was produced by mixing N-methylpyrrolidone (NMP) with a conductive material (furnace black, average primary particle size of 66 nm, manufactured by Tokai Carbon Co., Ltd.), a filler (alumina, CB-P02 manufactured by Showa Denko K. K.) and PVDF (KF polymer L #9130, manufactured by Kureha Corp.) so as to be conductive material:filler:PVDF=10:60:30 in the volume ratio. The both sides of an Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) were coated with the obtained paste so as each thickness after drying to be 10 μm, dried in a drying furnace, and coating layers were formed. Accordingly, an electrode was prepared.

Experimental Example 16

An electrode was prepared in the same manner as in Experimental Example 15 except that the volume ratio was changed to conductive material:filler:PVDF=8:70:22.

Experimental Example 17

An electrode was prepared in the same manner as in Experimental Example 15 except that the volume ratio was changed to conductive material:filler:PVDF=8:62:30.

[Evaluation]

A current breaking performance test was conducted for the electrode each prepared in Experimental Examples 15 to 17. Specifically, as shown in FIG. 9, test piece 30 including current collector (Al foil) 31 and coating layers 32 formed on the both sides thereof was prepared, Al foil 41 and SK material block 42 were placed in sequence on each of the two coating layers 32, and was bound by 60 MPa. A direct current was supplied in this situation, the resistance was determined from the change in voltage at that time. The measurement was conducted in an electric furnace, and the temperatures in the electric furnace were 25° C. and 200° C. The results thereof are shown in Table 7. Incidentally, the resistance values in Table 7 are relative values when the resistance in Experimental Example 15 at 25° C. is 1.

TABLE 7 Current collector Resistance Kind Coating composition (vol. ratio) 25° C. 200° C. R₂₀₀/R₂₅ Experimental C coated Al C:Al₂O₃:PVDF = 10:60:30 1 11.6 11.6 Example 15 Experimental C coated Al C:Al₂O₃:PVDF = 8:70:22 8.3 116 1 4.0 Example 16 Experimental C coated Al C:Al₂O₃:PVDF = 8:62:30 5.1 79.4 15.6 Example 17

As shown in Table 7, in Experimental Examples 15 to 17, every R₂₀₀/R₂₅ was 10 times or more, exhibiting high current breaking performance. When the temperature within a battery is raised due to a short circuit, for example, a current will be shut off by the resistance also being increased. Also, it was confirmed that the resistance differs according to the composition of the coating layer. From these results, it was suggested that, by making the current breaking performance of the current collector of the surface-side cell relatively high, and by making the current breaking performance of the current collector of the center-side cell relatively low, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

Experimental Example 18

An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was prepared as a cathode current collector. Meanwhile, a paste was produced by mixing N-methylpyrrolidone (NMP) with a conductive material (furnace black, average primary particle size of 66 nm, manufactured by Tokai Carbon Co., Ltd.), a filler (alumina, CB-P02 manufactured by Showa Denko K. K.) and PVDF (KF polymer L #9130, manufactured by Kureha Corp.) so as to be conductive material:filler:PVDF=10:60:30 in the volume ratio. A Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was coated with the obtained paste so as the thickness after drying to be 10 μm, dried in a drying furnace, and a coating layer was formed. The obtained Cu foil was prepared as an anode current collector.

Experimental Example 19

A paste was produced by mixing N-methylpyrrolidone (NMP) with a conductive material (furnace black, average primary particle size of 66 nm, manufactured by Tokai Carbon Co., Ltd.), a filler (alumina, CB-P02 manufactured by Showa Denko K. K.) and PVDF (KF polymer L #9130, manufactured by Kureha Corp.) so as to be conductive material:filler:PVDF=10:60:30 in the volume ratio. An Al foil (15 μm thickness, 1N30 manufactured by UACJ Corp.) was coated with the obtained paste so as the thickness after drying to be 10 μm, dried in a drying furnace, and a coating layer was formed. The obtained Al foil was prepared as a cathode current collector. Meanwhile, a Cu foil (12 μm thickness, electrolytic Cu foil manufactured by Furukawa Electric Co., Ltd.) was prepared as an anode current collector.

[Evaluation]

The contact resistance between the cathode current collector and the anode current collector each prepared in Experimental Examples 18 and 19 was measured. The contact resistance was measured by the method described above. The results thereof are shown in Table 8.

TABLE 8 Contact resistance Cathode current Anode current [Ω · cm²] collector collector 100 MPa Experimental Al C coated Cu 0.156 Example 18 Experimental C coated Al Cu 0.019 Example 19

As shown in Table 8, it was confirmed that the contact resistance differs by changing the current collector on which the coating layer is formed. From these results, it was suggested that, by making the contact resistance of the surface-side cell relatively high, and by making the contact resistance of the center-side cell relatively low, the unevenness of short circuit resistance among a plurality of cells may be suppressed.

REFERENCE SIGNS LIST

-   1 cathode active material layer -   2 anode active material layer -   3 solid electrolyte layer -   4 cathode current collector -   5 anode current collector -   10 cell -   100 stacked battery -   110 nail 

What is claimed is:
 1. A stacked battery comprising: a plurality of cells in a thickness direction, wherein the plurality of cells are electrically connected in parallel; each of the plurality of cells includes a cathode current collector, a cathode active material layer, a solid electrolyte layer, an anode active material layer, and an anode current collector, in this order; the stacked battery includes a surface-side cell that is located on a surface side of the stacked battery, and a center-side cell that is located on a center side rather than the surface-side cell; a contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than a contact resistance between the cathode current collector and the anode current collector in the center-side cell, wherein the contact resistance pertains to a physical contact between the anode current collector and the cathode current collector; the total cell number included in the stacked battery is 3 or more; when the contact resistance between the cathode current collector and the anode current collector in the surface-side cell is R_(c1), and the contact resistance between the cathode current collector and the anode current collector in the center-side cell is R_(c2), R_(c1)/R_(c2) under pressure of 100 MPa is in a range of 1.5-10,000; the solid electrolyte layer includes an inorganic solid electrolyte material as a solid electrolyte material; and the surface-side cell and the center-side cell satisfying at least one of the following conditions: i) a material for the cathode current collector in the surface-side cell is different from a material for the cathode current collector in the center-side cell; and ii) a material for the anode current collector in the surface-side cell is different from the material for the anode current collector in the center-side cell.
 2. The stacked battery according to claim 1, wherein at least one of the cathode current collector and the anode current collector in the surface-side cell includes, on a surface thereof, an oxide layer.
 3. The stacked battery according to claim 1, wherein the cathode current collector in the surface-side cell includes, on a surface thereof, a first coating layer containing a carbon material, and the cathode current collector in the center-side cell includes, on a surface thereof, a second coating layer containing a carbon material.
 4. The stacked battery according to claim 3, wherein a content of the carbon material in the first coating layer is less than a content of the carbon material in the second coating layer.
 5. The stacked battery according to claim 3, wherein a thickness of the first coating layer is more than a thickness of the second coating layer.
 6. The stacked battery according to claim 3, wherein, when a proportion of a resistance R₂₀₀ at 200° C. with respect to a resistance R₂₅ at 25° C. is R₂₀₀/R₂₅, the R₂₀₀/R₂₅ value of the first coating layer is more than the R₂₀₀/R₂₅ value of the second coating layer.
 7. The stacked battery according to claim 1, wherein the anode current collector in the surface-side cell includes, on a surface thereof, a third coating layer containing a carbon material, and the anode current collector in the center-side cell includes, on a surface thereof, a fourth coating layer containing a carbon material.
 8. The stacked battery according to claim 7, wherein a content of the carbon material in the third coating layer is less than a content of the carbon material in the fourth coating layer.
 9. The stacked battery according to claim 7, wherein a thickness of the third coating layer is more than a thickness of the fourth coating layer.
 10. The stacked battery according to claim 7, wherein, when a proportion of a resistance R₂₀₀ at 200° C. with respect to a resistance R₂₅ at 25° C. is R₂₀₀/R₂₅, the R₂₀₀/R₂₅ value of the third coating layer is more than the R₂₀₀/R₂₅ value of the fourth coating layer.
 11. The stacked battery according to claim 1, wherein: one of the cathode current collector and the anode current collector in the surface-side cell includes, on a surface thereof, a coating layer containing a carbon material, and another does not include, on a surface thereof, a coating layer containing a carbon material; and one of the cathode current collector and the anode current collector in the center-side cell includes, on a surface thereof, a coating layer containing a carbon material, and another does not include, on a surface thereof, a coating layer containing a carbon material in reverse to the surface-side cell.
 12. The stacked battery according to claim 1, wherein, when each of the plurality of cells is numbered as 1^(st) cell to N^(th) cell, in which N≥3, in order along the thickness direction of the stacked battery, the surface-side cell is a cell that belongs to a cell region A including 1^(st) cell to (N/3)^(th) cell.
 13. The stacked battery according to claim 12, wherein the center-side cell is a cell that belongs to a cell region B including ((N/3)+1)^(th) cell to (2N/3)^(th) cell.
 14. The stacked battery according to claim 13, wherein an average value of the contact resistance in the cell region A is more than an average value of the contact resistance in the cell region B.
 15. The stacked battery according to claim 1, wherein, when each of the plurality of cells is numbered as 1^(st) cell to N^(th) cell, in which N≥60, in order along the thickness direction of the stacked battery, the surface-side cell is a cell that belongs to a cell region C including 1^(st) cell to 20^(th) cell.
 16. The stacked battery according to claim 15, wherein the center-side cell is a cell that belongs to a cell region D including 21^(st) cell to 40^(th) cell.
 17. The stacked battery according to claim 16, wherein an average value of the contact resistance in the cell region C is more than an average value of the contact resistance in the cell region D.
 18. The stacked battery according to claim 1, wherein the anode active material layer includes Si or a Si alloy as an anode active material.
 19. The stacked battery according to claim 1, wherein the value of R_(c1) under pressure of 100 MPa is 0.037 Ω·cm² or more and 0.277 Ω·cm² or less.
 20. The stacked battery according to claim 1, wherein, in a state in which a nail penetration test has been conducted, the contact resistance between the cathode current collector and the anode current collector in the surface-side cell is more than the contact resistance between the cathode current collector and the anode current collector in the center-side cell. 